SHOP MANUAL

AUIS-CHALMERSMODELS 180, 185, 190, 190XT, 200, 7000

INDEX (By Starting Paragraph)

BELT PULLEY 150 ENGINE (DIESEL) CONT.

BRAKES180 and 185 141190, 190XT and 200 144, 1467000 148

CLUTCHEngine clutch 85Engine clutch shaft 89"Power-Director" clutch 93"Power Shift" dutches 101

COOLING SYSTEMWater pump , , . 79Oil cooler 75Radiator .78

DIESEL FUEL SYSTEMFilters and bleeding 60Injection pump 70Injection pump gears 33, 33ANozzles 62

DIFFERENTIALAdjustment 124R&R and overhaul 125

ELECTRICAL 81

ENGINE (DIESEL)Assembly—R&R 20Cam followers 26Camshaft 36Connecting rods & bearings 41Crankshaft and bearings 42Cylinder head 21Cylinder sleeves 39Flywheel . . . . . 45Front oil seal 43Injection timing 70Main bearings 42Oil pan 46Oil pump 47, 47APiston pins 40Piston & rod removal 38Pistons and rings 39

Rear oil seal 44Rocker arms 27Speed adjustments 72Timing gear cover 29Timing gears 30Turbocharger 73Valve clearance 28Valve guides 24Valves & valve seats 22Valve springs 25Valve timing 30

ENGINE (NON DIESEL)Assembly—R&R., 20Cam followers 26Camshaft 36Connecting rods & bearings 41Crankshaft & bearings 42Cylinder head ., 21Cylinder sleeves 39Flywheel 45Front oil seal 43Ignition timing 83Main bearings 42Oil pan 46Oil pump .47Piston pins 40Piston & rod removal 38Pistons & rings 39Rear oil seal 44Rocker arms 27Spark plugs 81Speed adjustment 76Timing gear cover 29Timing gears 30Valve clearance 28Valve guides 24Valves & valve seats 23Valve springs 25Valve timing 30

FINAL DRIVE & DIFFERENTL^LBevel gears adjust 128Bull gear renew 131, 137Bull pinion renew 133, 136Differential overhaul 125Wheel axle shafts 131, 139

FRONT SYSTEMAdjustable axle 5Dual wheel tricycle 3Single wheel tricycle 1

GASOLINE tUEL SYSTEMCarburetor 49Fuel pump 51

GOVERNOR (NON DIESEL)Adjustment 76Overhaul 77

IGNITION SYSTEMDistributor 82Ignition timing 83

LP GAS SYSTEMAdjustments 52Carburetor 53Filter 56Regulator 54

"POWER DIRECTOR''Clutch 93Control valve .92Shafts and gears 95

"POWER SHIFT"Clutches 101Control valves 100Shafts and gears 103

POWER LIFT SYSTEMPump 184Testing 174Work cylinders 193

POWER TAKE-OFF 154

STEERING SYSTEM 11

TRANSMISSIONBevel pinion shaft 110, 115, 120Countershaft 112. 117, 122Input shaft 109, 114, 119Reverse idler 113, 118, 123Shifter assembly 107, 108

CONDENSED SERVICE DATA

180, 185 & 190 One-Ninety XTGasoUne Diesel Gasoline LP-Gas Diesel

GENERALEngine Make Own Own Own Own OwnEngine Model G2500 2800 G2800XT G2800LPXT 2900XTNumber of Cylinders 6 6 6 6 6Bore-Inches 3% 3-7/8 3-7/8 3-7/8 3-7/8Stroke-Inches 4 47* 4V4 4V4 4V4Displacement-Cubiclnches 265 801 301 301 301Main Bearings, Number of 7 7 7 7 7Cylinder Sleeves Wet Wet Wet Wet WetGenerator and Starter Make Delco-Remy Delco-Remy Delco Remy Delco-Remy Delco-Remy#Some models are equipped with a Lucas starter.

TUNE-UPFiring Order 1-5 3-6-2 4 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4Valve Tappet Gap (Hot) Intake 020 .015 .020 .020 .015Valve Tappet Gap (Hot) Exhaust... .025 .015 .025 .025 .015Inlet Valve Seat Angle (Degrees)... 30 80 80 30 80Exhaust Valve Seat

Angle (Degrees) 45 45 45 45 45Ignition Distributor Make D-R ... D-R D-RBreaker Gap 016 ».. .016 .016Ignition Timing at 2200 rpm 26** BTDC ... 26° BTDC 26-28*» BTDCTiming Mark Location Crankshaft Pulley Crankshaft PulleySpark Plug—

AC 45XL ... 45XL 42XLAutolite AG-3A ... AG-3AChampion N-6 ...• N-6 N-3

Electrode Gap 025 ... .025 .020Injection Timing

190, 190XT and 200 ... 28*̂ BTDC ... ... 26° BTDC180, 185 and 7000 26° BTDC

Injection Pump Make ... Roosa-Master ... ... Roosa-MasterCarburetor Make HoUey ... Holley EnsignCarburetor Model 1970 ... 1970 CBXBattery Terminal, Grounded Neg. Neg. Neg. Neg. Neg.Engine Low Idle rpm 425t 675 425 425 675Engine High Idle rpm, No Load . . . . 2450t 2400tt 2450 2450 2400Engine Full Load rpm 2200ttt 2200ttt 2200 2200 2200

tRefer to paragraph 76 for 180 non-diesel. JtRefer to paragraph 72 for 180 diesel.tttFull load rpm should be 2000 for all 180 models. ##Model 200 after serial no. 2D-69515 same as 7000.

SIZES-CAPACITIES-CLEARANCES(Clearances in Thousandths)Crankshaft Main Journal Diameter . 2.7475 2.7475Crankpin Diameter 2.373 2.373Camshaft Journal Diameter, Al l . . . . 2.1305 2.1305Piston Pin Diameter 1.2516 1.2516Valve Stem Diameter, Inlet 0.3717 0.3717

Exhaust 0.3707 0.3707Main Bearing Diametral Clearance.. 1.6-4.3 1.6-4.3Rod Bearing Diametral Clearance... 0.9-3.4 0.9-3.4Piston Skirt Diametral Clearance... 1.5-4.0 3.5-6.0 1.5-4.0 1.5-4.0 3.5-6.0Camshaft End Play 4-9 4-9Camshaft Bearings Diametral

Clearance 2-6 2-5Camshaft End Play 3-9 3-9Cooling System Capacity, Quarts . . . 18 18*Crankcase Oil, Quarts 8-12** 8-12**Power-Director and

Hydraulic System, Quarts 24-36** 24-36**Transmission, Quarts 27-32** • 27-32**Final Drive, Quarts (each) 8*** 8

*Capacity 22.5 qts. on 7000.**Approximate capacity.***Capacity 1 quart on 180 and 185 models.

200,7000

Own2900

63-7/84V43017

WetDelco-Remy #

1-5-3-6-2-4.015.01530

45

24° BTDC##18° BTDC

Roosa Master

Neg.77524002200

4.5-7.0

26-28**32-38**

Paragraphs 1-3 ALLIS-CHALMERS

CONDENSED SERVICE DATA CONT.TIGHTENING TORQUES-FOOT-POUNDSGeneral Recommendations....Connecting Rod ScrewsCylinder Head ScrewsFlywheel ScrewsInjection Nozzel NutsMain Bearing Screws .

—40-45-—150_68-73—

9-12-130-140-

See End of Shop Manual—40-45-—150—--68-73—

9-12 11-13-130-140-

FRONT SYSTEM

SINGLE WHEEL TRICYCLE

1. WHEEL ASSEMBLY. The singlefront wheel assembly may be removedafter raising front of tractor and re-moving bolt (3—Fig. 1) at each end ofwheel axle (1).

To renew bearings and/or seals, firstremove wheel assembly; then unboltand remove bearing retainer (10—Fig.2), seal (4), seal retainer (5) and shims(9). Drive or press on opposite end toremove axle (8), bearing cones (7) andbearing cup from retainer side of hub.Drive the remaining seal and bearingcup out of hub. Remove bearing conesfrom spindle.

Soak new felt seals in oil prior toinstalling seals and seal retainers.Drive bearing cup into hub until cup isfirmly seated. Drive bearing conestightly against shoulders on axle. Packbearings with No. 2 wheel bearinggrease. Install axle and bearing cup inagainst cone. When installing bearingretainer, vary number of shims (9—Fig.2) to give bearings a free rolling fitwith no end play.

Front wheel bearings should berepacked with No. 2 wheel bearinggrease after each 500 hours of use.

If necessary to renew wheel hub orrepair tire, deflate tire before unbolting

Fig. t~'Explod9<l vf9W of th0 single frontfork and associatBd parts.

Fig. 2^Exf>lod9d fiaw of singla front wheel assembly.

1. Side rings (2)2. Tire3. Wheel hub

4. Seals (2)5. Seal reUiners (2)

and removing tire retaining rings(1-Fig. 2).

2. R&R SINGLE WHEEL FORK.Raise front end of tractor, remove bolts(3—Fig. 1) from each end of wheel axleand remove wheel assembly from fork.Unbolt and remove fork (2) fromsteering gear shaft.

Make sure that steering gear is cen-tered and reinstall fork with caster torear. Tighten retaining screws to atorque of 180-190 ft.-lbs.

Fig. 3—Dual wheel tricycle spindles (2) canbe removed after removing groove pins {$).

1. Axle2. Fork 3. BolU {2)

1. Pedestal2. Spindle3. Shield

6. Bearings cups (2)7. Bearing cones (2)

8. Axle9. Shims

10. Bearing retainer

DUAL WHEEL TRICYCLE

3. WHEEL ASSEMBLY. Thestamped steel wheel disc is reversibleon hub. Bearing adjustment is made bytightening retaining nut on spindleuntil bearings are firmly seated, back-ing nut off one castellation and in-stalling cotter pin. Bearings should berepacked with No. 2 wheel bearinggrease after each 500 hours of use.

Dual wheel pedestal spindles areequipped with an external lip type seal(1—Fig. 4). The three lips on outsidediameter of seal contact a steel wearsleeve that is pressed into the frontwheel hub. Drive wear sleeve into hubwith crimped edge of wear sleeve

Fig. 4—Expioded view of wheel hub andbearing used on dual wheel tricycle and wide

front axle modeis.

4. Beaiing spacer5. Groove pin

1. Wear sleeve andseal

2. Inner bearing3. Wheel hub

4. Outer bearing5. Washer6. Nut7. Hub cap

180-185-190-190XT.200.7000 Paragraphs 4-8

towards bearing until sleeve is V4 inchbelow flush with hub.

4. R&R PEDESTAL. Raise front oftractor, then remove cap screws retain-ing pedestal (1—Fig. 3) to steering gearshaft.

When reinstalling, make certain thatthe steering gear shaft is centered andinstall pedestal with wheels in straightahead position and caster to rear.Tighten retaining screws to 130-140ft.-lbs. torque.

ADJUSTABLE FRONT AXLE

5. WHEEL ASSEMBLY. Refer toFig. 4. Stamped wheel disc is reversibleon hub. Bearing adjustment is made bytightening retaining nut on spindleuntil bearings are firmly seated, back-ing nut off one castellation and in-stalling cotter pin. Bearings should berepacked with No. 2 wheel bearinggrease after each 500 hours of use.

Crimped edge of seal shell should betowards shoulder on spindle whenrenewing seal (lettered side of sealshell towards bearing).

6. AXLE ADJUSTMENTS. The ad-justable front axle provides wheeltread widths of 62-86 inches on 7000models and 60-84 inches on all othermodels. Front wheels may be mountedinside out on some models to increasetread width.

Tie rods are grooved or threaded tofacilitate toe-in adjustment; however, itmay be advisable to measure frontwheel toe-in and adjust to 1/16 to 1/8inch. Tighten bolts in tie rod clampssecurely.

7. AXLE CENTER (MAIN) MEM-BER AND RADIUS ROD ASSEMBLY.Support front end of tractor and re-move bolts through center member andaxle extensions (spindle supports).Loosen or remove bolts in tie rodclamps and slide axle extension (7—Fig.5 or 5A) with front wheels and spindlesout of main member and tie rod shaftsout of tie rod tubes. Remove externalpower steering cylinder on models soequipped. On all models, place floorjack under center member and removepivot pin (2—Fig. 5A) on 7000 modelsor rear pivot screw (4—Fig. 5) andfront pivot pin (2) on all other models.Lower the axle until it clears the pivotbrackets, then pull center member outfrom under tractor.

Bushing (3—Fig. 5) on all modelsexcept 7000 is pre-sized and if carefullyinstalled should not need reaming.Pivot pin (2) should have 0.012-0.015clearance in bushing (3) and 0.005-0.009clearance in front support bore.

Reverse removal procedure to installnew center member.

Fig, 5—Exploded view of adiustabh front axle assembly used on all models except 7000:Steering arm 04) Is used with internal cylinder type front support (Fig. 12), Steering arm (iS)

I9 U99d with external cylinder type steering (Ffg. IT).

1. Snap ring2. Axle front

pivot pin3. Bushing

4. Rear pivotscrew

5. Rear pivotbracket

6. Axle mainmember

7. Axle extension8. Snap rings9. Spindle bushings

10. Spindle arm11. Thrust washers12. Key13. Spindle16. Tie rod

8. SPINDLE BUSHINGS. Supportfront end of tractor and remove frontwheels. Remove snap ring (8—Fig. 5 or5A), spindle arm (10) and Woodruffkey (12). Spindle can then be removedfrom bottom of axle extension (spindlesupport). Drive bushings (9) from topand bottom of spindle bore and remove

thrust washers (11) from spindles.

New spindle bushings are pre-sizedand should not require reaming. Pressor drive bushings into support flushwith ends of spindle bore. Install twothrust washers on spindle and reas-semble.

16

Fig. SA-^Explod^d view ofadiustBbl9 front axle as-sembly used on Model7000. Refer to Fig. 5 forparts Identification exceptfor: t7. Cylinder brackets;18. Power steering cylin-

der; 19. Ti9 rod 9nd,

Paragraphs 9-13 ALLIS-CHALMERS

FRONT SUPPORT

Models With ExternalSteering Cylinder

9. REMOVE AND REINSTALL. Toremove front support casting from ad-justable front axle models with anexternal steering cylinder, proceed asfollows: Remove hood, grille and hoodside panels. Drain cooling system andremove air cleaner and air cleanertube. Disconnect hoses and removeradiator. Disconnect steering cylinder.Remove radius rod pivot pin. (4—Fig.5) on all models except 7000 models.Support tractor under torque housingso there is no weight on front wheels.Attach a hoist to front support, removecap screws attaching front support,to side rails and roll front support andaxle away from tractor.

NOTE: If front support casting bindsbetween the side rails, loosen the boltsattaching side rails to the engine frontsupport plate. Front support castingcan be separated from axle assemblyafter removing pivot pin.

When reinstalling, tighten the radiusrod pivot screw (4—Fig. 5) on allmodels except 7000 models to at least150 ft.-lbs. Tighten cap screws attach-ing side rails to the engine frontsupport plate to 70-75 ft.-lbs. Ontractors prior to Serial No. 190 2807,tighten the eight 5/8-inch screwsattaching side rails to front support to130-140 ft.-ibs torque. On tractors afterSerial No. 190-2806, and all model 200tractors, tighten side rail to frontsupport %-inch cap screws to 310-320ft.-lbs. torque.

Models With intemai (Dual)Steering Cylinders

10. REMOVE AND REINSTALL.The front support casting (5—Fig. 12)on all tricycle models and some adjust-able axle models is used as the steeringcylinder. To remove the front support,proceed as follows: Remove hood, grilleand hood side panels. Drain coolingsystem and remove air cleaner and aircleaner tube. Disconnect hoses andremove radiator. Disconnect the steer-ing hydraulic lines from "Tee" fittingson front support. On adjustable frontaxle models, remove radius rod pivotpin (4—Fig. 5). On all models, supporttractor under torque housing So thereis no weight on front wheels. Attach ahoist to the front support, remove capscrews attaching front support to siderails and roll the front support andwheels away from tractor.

NOTE: If front support casting bindsbetween side rails, loosen boits attach-ing side rails to engine front supportpiate.

When reinstalling, tighten cap screwsattaching side rails to engine frontsupport plate to a torque of 70-75ft.-lbs. On tractors prior to Serial No.190 2807, tighten the eight (5/8-inch)cap screws attaching side rails to frontsupport to 130-140 ft.-lbs of torque. Ontractors after Serial No. 190-2806, andall model 200 tractors, tighten side railto front support (V4 4nch) cap screws to310-320 ft.-lbs. torque. On adjustablefront axle models, radius rod pivot pinshould be tightened to at least 150ft.-lbs. torque.

STEERING SYSTEMAll models are equipped with hydro-

static steering system that has nomechanical linkage between the steer-ing wheel and front axle. The controlvalve unit (Fig. 9) contains a rotarymetering motor, a commutator feedvaive sleeve and a selector valve spool.In the event of engine or hydraulicpower failure, the metering motorbecomes a rotary pump to actuate thepower steering cylinder when the steer-ing wheei is turned. A checi( vaive inthe control valve housing allows re-circuiation of fiuid within the controlvalve and steering eyiinder duringmanual operation.

Power for the steering system issupplied by a gear type pump that isdriven from the engine camshaft gear.The power steering pump aiso supplieshydraulic pressure to "Power-Director"ciutch and hydraulic pto clutch sys-tems.

TROUBLE SHOOTING

11. Before attempting to adjust orrepair the power steering system, thecause of any malfunction should be lo-cated. Refer to the following para-graphs for possible causes of powersteering system malfunction:

Irregular or "Sticky" steering. If ir-regular or "sticky" feeling is notedwhen turning the steering wheel withforward motion of tractor stopped andwith engine running at rated speed, orif steering wheel continues to rotateafter being turned and released, foreignmaterial in the power steering fluid isthe probable cause of trouble. Cleanthe magnetic oil filter, renew throw-away type oil filter, drain "Power-Director" compartment (hydraulicsump) and refill with clean oil. Iftrouble is not corrected, the powersteering valve assembly should be re-moved and serviced; refer to paragraph15.

Steering Cylinder ''Hesitates**. Ifsteering cylinder appears to pause intravel when steering wheel is beingturned steadily, probable cause oftrouble is air trapped in the powersteering cylinder. Bleed the cylinder asoutlined in paragraph 12.

Slow Steering. Slow steering may becaused by low oil flow from pump.Check time required for full stroketravel of jwwer steering cylinder; firstwith tractor on the front wheels, thenwith front end of tractor supported bya jack. If time between the two checksvaries considerably, overhaul the powersteering pump as outlined in paragraph186.Loss of Power. Loss of steering powermay be caused by system pressure toolow. Check and adjust relief valvesetting as outlined in paragraph 13,13A or 13B.

LUBRiCATiON AND BLEEDiNG

12. The "Power-Director" compart-ment of the torque housing is utilizedas a reservoir for the hydraulic systemsincluding power steering. Capacity isapproximately 28 quarts for 190,190XT,200 and 7000 models, 24 quarts for 180and 185 models. Oil level on all modelsexcept 7000 should be maintained atmark on filler cap dipstick located toleft and forward of gear shift. On 190,190XT and 200 models, it is necessaryto remove rear section of gear shiftlinkage cover for access to dipstick. Oillevel on 7000 models should be main-tained between two sight glass gageson right side of torque housing.Allis-Chalmers "Power Fluid" should beused.

The power steering system is usuallyself-bleeding. With engine running athigh idle speed, cycle the systemthrough several full strokes of thecylinder. In some cases, it may benecessary to loosen connections atcylinder to bleed trapped air.

TESTS AND ADJUSTMENTS

190 and 190XT Models13. The "Power-Director" clutch and

(on models so equipped) the pto clutchare actuated by pressure from thepower steering system. Before check-ing the power steering relief pressure,refer to paragraphs 91 and 155 to checkthe "Power-Director" and pto pres-sures.

A pressure and volume (flow) test ofthe power steering system will disclosewhether the pump or relief valve ismalfunctioning. To make such a test,proceed as follows:

Remove hood right side paneland disconnect steering system return

6

180-185-190-190XT.200-7000 Paragraphs 13A

Fig. e—View ot OTC pres-sure-volume tester con-rtected for checking powersteering system on 190and 190XT tractors. Openend of "Tee" fitting mustbe capped before engine

is started.

hose from "Tee" fitting shown in Fig. 6. fitting. Connect a pressure-volumeInstall a cap over open end of "tee" tester inlet hose to steering system

return hose as shown. Position outlethose from tester in the "Power-Direc-tor" filler opening so that oil will bereturned to the reservoir. Make certainthat "Power-Director" control lever isin neutral and pto control is in neutral(not brake position). Start engine andand adjust speed to 1600 rpm. Closevalve on tester until pressure is 1200psi and allow oil temperature to reach100 degrees F.

Close the valve on tester completelyand check pressure gage. If relief pres-sure is not 1500 psi. remove plug (11—Fig. 6A) and add or deduct shims (9) toset pressure.

To check volume, open the valve ontester until pressure is approximately1200 psi and observe the volume offlow. With engine operating at 1600rpm, volume should be 5.25 gpm. Ifvolume of flow is incorrect, the flowcontrol valve (4) or pump should beserviced as outlined in paragraph 186.

180 and 185 Models13A. The "Power-Director*' clutch

and (on models so equipped) the ptoclutch are actuated by pressure fromthe power steering system. Beforechecking the power steering reliefpressure, refer to paragraphs 91 and157 to check the "Power-Director" andpto pressures.

A pressure and volume (flow) test ofthe power steering system will disclosewhether the pump or relief valve ismalfunctioning. To make such a test,proceed as follows:

Remove cover from below instru-ment panel and disconnect steeringsystem return tube from "tee" fittingshown in Fig. 7. Install a cap over openend of "Tee" fitting. Connect a pres-sure-volume tester inlet hose to steer-ing system return tube as shown.Position outlet hose from tester in thetorque housing filler opening so that oilwill be returned to hydraulic reservoir.Start the engine and adjust speed torated rpm (2000 rpm on 180 models;2200 rpm on 185 models). Close valveon tester until pressure is 1200 psi andallow oil temperature to reach 120-135degrees F.

Close the valve on tester completelyand check pressure gage. If relief pres-sure is not 1500-1600 psi, remove anddisassemble the relief valve (Fig. 7).Add or deduct shims (5—Fig. 7A) toset pressure. Addition of one shim

Fig. BA—Expioded view of hydraulic pumpmanifold used on 190 models showing powersteering flow control vaive (4) and pressure

relief valve (7).

1. Plug2. "0" ring3. Spring4. Flow control

valve5. Pump manifoldQ. Bushing

7. Pressure reliefvalve

8. Spring9. Shims

10 Gasket11. Plug

Fig. T—Vlew of OTC pres-sure-volume tester con-nected for checking powersteering system on 180and 185 modeis, it isnecessary to loosen upper(control vaive) end andmove the tube siightiy sothat inlet hose to testercan be attached. Makecertain that upper end oftube is tight and that "T"fitting is capped beforestarting engine. Reiiefvalve is located between

the two «T" fittings.

Paragraphs 13B-16 ALLIS-CHALMERS

should raise pressure approximately 50psi.

To check pump volume, open thevalve on tester until pressure is ap-proximately 200-300 psi below reliefvalve setting and observe volume offlow. With engine operating at ratedspeed (2000 rpm on 180 models ; 2200rpm on 185 models), pump volumeshould be approximately 5.8 gpm. Ifvolume is too low, the pump should beserviced as outlined in paragraph 189.

200 And 7000 Models13B. The pto clutch (on models so

equipped) is operated by return or by-pass oil from the power steeringsystem. Pto clutch operating pressuremust be tested as outlined in para-graphs 91 and 155 on model 200 orparagraphs 99 and 159 on Model 7000before checking power steering reliefpressure.

Power steering relief valve pressurecan be checked by installing a highpressure (3000 psi) hydraulic gage inport (P—Fig. 8) after removing theplug. Turn the steering wheel briefly toone end of its travel and observepressure. If tractor is not equippedwith pto, power steering relief pres-sure should be 1575-1725 psi. If tractoris equipped with pto, relief pressure

Fig. 7A—Exploded view of the powering reiief valve used on 180 and 18S models.

Refer to Fig. 7 for location.

1. Relief valve2. "0" ring 4. Spring3. BaU 5. Shims

Fig. 8—Power steering pressure can becfiecked at port (P) on 200 and 7000 tractors.Relief valve is iocated on engine side ofpump. Adfusting screw (S) and cap nut (C)

are used on early 200 models.

should be 1400 psi on 7000 models and1865-2015 psi on Model 200. Powersteering relief pressure can be adjustedat screw (S) on early 200 models afterremoving cap nut (C). Relief pressureon 7000 and later 200 models isadjusted using shims.

The flow divider located in pumprear cover first supplies oil through theoil cooler to the power steering valve.Rate of flow is 4.25 gpm on Model 200serial numbers prior to 200-4001, 6 gpmon Model 200 serial numbers 200-4001and up and 8 gpm on Model 7000. Ahydraulic flo-rater can be attached toport (P—Fig. 8) with outlet fromflo-rater routed to sump filler opening.With engine operating at approximately1600 rpm, first check relief pressure.Refer to preceding paragraph forrecommended settings. Open flo-ratervalve and turn steering wheel to fullleft or right and note gage reading.Volume should be 4.25 gpm for Model200 serial numbers prior to 200-4001, 6gpm for model 200 serial numbers200-4001 and up and 8 gpm for Model7000 with engine speed between 800and 2200 rpm.

Caution: Use of flo-rater with steer-ing in fuli left or right position disruptsoii circuit flow and shouid not becontinued for extended periods.

The pump and/or flow divider valveshould be serviced if volume of flow isincorrect.

5A

POWER STEERING PUMP

14. A gear type pump driven fromthe engine camshaft gear is used as thepower source for the steering system.The power steering pump is an integralpart of the hydraulic system pump andthe "Traction Booster" pump. Forservice information on pump, refer toparagraph 184.

CONTROL VALVE

15. REMOVE AND REINSTALL. On190, 190XT, 200 and 7000 models,remove hood. On 180 and 185 models,remove cover from below instrumentpanel. On all models, disconnect hoses(or tubes) from control valve, thenunbolt and remove control valve fromthe steering shaft housing.

Reinstall the control valve assemblyby reversing the removal procedure.Refer to Fig. 10 for proper hose (ortube) locations. Install new "0" ringseals on fittings before connecting tocontrol valve and tighten fittingssecurely. Bleed trapped air from thepower steering cylinder as outlined inparagraph 12 after assembly is com-pleted.

16. OVERHAUL. After removingcontrol valve assembly, clean valvethoroughly and remove paint frompoints of separation with wire brush.

NOTE: Mal(e certain that work area isciean and use oniy lint free paper shoptoweis for cieaning valve parts.

If oil leakage past seal (1—Fig. 9) isthe only difficulty, a new seal can beinstalled after removing only the

14

15

21

Fig. 9^Exploded view of steering controi valve assembly. Centering springs (12) are installedIn two groups of three springs with arch in each group back-to^back.

1. on seal2. Mounting plate3. Quad ring seal4. **O"ring

5A. Bearing races5B. Thrust bearing

6C. Locatorbushing

6. "0" ring7. Plug8. Check seat9. Check valve

10. Valve spring

11. Control valvebody

12. Centeringsprings (6)

13. Centering pin14. Sleeve

15. Valve spool16. Plate17. Drive shaft18. Rotor19. Ring20. Spacer21. Cover (cap)

8

180-185-190-190XT-200-7000 Paragraphs 17-18

mounting plate (2). Remove plug (7)from valve body using a bent wireinserted through out port (Fig. 10). In-stall new "0" ring (6—Fig. 9) on plug,lubricate plug and "0" ring with oil andreinstall in valve body. Install newquad seal (3) and "0" ring (4) inmounting plate and tighten retainingcap screws equally to a torque of 250inch-pounds.

To completely disassemble and over-haul the control valve, refer to ex-ploded view in Fig. 9 and proceed asfollows: Clamp valve in vise with endcap (21) up and remove end capretaining screws. Remove end cap (21),gerotor set (18 & 19), plate (16) anddrive shaft (17) from valve body as aunit. Remove valve from vise, place aclean wood block in vise throat and setvalve assembly on block with mountingplate (2) end up. Lightly clamp viseagainst port face of valve body and re-move mounting plate retaining screws.Hold spool assembly down againstwood block while removing mountingplate. Remove valve body from viseand place on work bench with port facedown. Carefully remove spool andsleeve assembly from 14-hole end ofvalve body. Use bent wire insertedthrough outlet port to remove checkvalve plug (7) and use 3/16-inch Allenwrench to remove check valve seat (8).Then remove check valve V4-inch steelball (9) and spring (10) from valvebody.

Remove centering pin (13) from spooland sleeve assembly, and push spool(splined end first) out of sleeve.Remove the six centering springs (12)from slot in spool.

Separate the end cap and plate fromthe gerotor set and remove the driveshaft, rotor and spacer.

Inspect all moving parts for scoring.Slightly scored parts can be cleaned byhand rubbing with 400 grit abrasivepaper. To recondition gerotor sectionsurfaces place a sheet of 600 grit paperon plate, glass, lapping plate or otherabsolutely flat surface. Stroke eachsurface of the gerotor section over theabrasive; any small bright areas indi-cate burrs that must be removed.Polish each part, rinse in clean solventand air dry; keep these parts ab-solutely clean for reassembly.

Renew all parts that are excessivelyworn, scored or otherwise damaged.Install new seal kit when reassembling.

To reassemble valve, proceed asfollows: Install check valve spring (10)with small end out. Drop check valveball (9) on spring and install valve seat(8) with counterbored side towardsvalve ball. Tighten seat to a torque of150 inch-pounds. Lubricate valve spooland carefully insert spool (15) in valvesleeve (14) using a twisting motion.Stand the spool and sleeve assembly onend with spring slots up and aligned.Assemble centering springs (12) in twogroups with extended edges of springsdown. Place the two groups of springsback-to-back (arched sections together)and install the springs into the springslots in sleeve and spool in thisposition. Use a small screwdriver toguide springs through slots in oppositeside of assembly. Center the springswith edges flush with upper surface ofsleeve. Insert centering pin (13)through spool and sleeve assembly sothat both ends of pin are below flushwith outside of sleeve (14).

NOTE: On some models, a smailnyion piug is iocated at each end ofcentering pin (13) to prevent contactwith vaive body.

Carefully insert spool and sleeve as-sembly, splined end first, in 14-hole endof valve body (11). Set body on cleansurface with 14-hole end down. Installnew "0" ring (6) in check valve plug(7), lubricate plug and insert in checkvalve bore. Install locator (5C) in valvebore with chamfered side up. Installthrust bearing assembly (5A and 5B)

over valve spool (15). Install new quadseal (3) and "0" ring (4) in mountingplate (2), lubricate seal and installmounting plate (2) over valve spool,thrust bearing and locator. Tighten themounting plate retaining screws evenlyto a torque of 250 inch-pounds. Clampthe mounting plate in a vise with 14-hole end of valve body up. Place plate(16) and gerotor outer ring (19) onvalve body so that bolt holes align.Insert drive shaft (17) in gerotor innerrotor (18) so that slot in upper end ofshaft is aligned with valleys in rotorand push shaft through rotor so thatabout V2 of length of the splines pro-trude. Holding the shaft and rotor inthis position, insert them in valvehousing so that notch in shaft engagescentering pin in valve sleeve and spool.Install spacer (20) at end of drive shaft;if spacer does not drop down flush withrotor, shaft is not properly engagedwith centering pin. Install end cap (21)and tighten the retaining screwsequally to 150 in.-lbs. torque.

STEERING CYLINDER

External Cylinder17. REMOVE AND REINSTALL.

Thoroughly clean cylinder and hosefittings to avoid entry of dirt whenlines are disconnected. Disconnect hosefittings at cylinder and remove cylinderfrom tractor. Work the cylinder pistoneach way to end of stroke to expel allexcess oil.

When reinstalling cylinder, first at-tach hose fittings leaving the flare nutsloose. Install cylinder to crossbar andpiston rod to steering arm, thentighten nuts and secure with cotterpins. Check to see that hoses areproperly located, then tighten the flarenuts.

Bleed the power steering system asoutlined in paragraph 12, check the"Power-Director" (hydraulic reservoir)oil level and add fluid as necessary tobring oil level to full mark on dipstick.

18. OVERHAUL. MODEL 1000. Re-move steering cylinder as previouslyoutlined and proceed as follows: Re-move snap ring (11—Fig, 11). Push rod

Fig. 10—View of steering controi vaiveshowing port locations. Pressure tube frompump connects to "iN" port; return tube tosump connects to "OUT" port; tube to rearend of cylinder connects to "L" {left turn)port; and tube to rod end of cylinder

connects to "R** {right turn) port.

1 3 6 7 8 9Fig. 11—Cross-section view of power steering cylinder used on Model 7000.

l .Nut2. Back-up ring3. "0" ring4. Piston

5. Piston rod6. CyUnder7. Rod guide

8. "0" ring &back-up ring

9. Seal

10. Sniq) ring11. Snap ring12. Wiper seal

Paragraph 19 ALLIS-CHALMERS

1. Cylinder2. Bushings

(2 used)3. Piston rod

Fig. HA—Cross section of externai steering eyiinder. Refer to text.

4. Wiper seal5. Back up ring6. "0" ring7. Snap ring

8. Fitting9. Tube seats

(2 used)

10. Back up ring11. "0" ring12. Rod p i d e

bushing

13. Piston14. Wear rings

(2 used)15. "0" ring

16. Sealing ring17. Cap screw

(or nut)

guide (7) into cylinder until snap ring(10) is accessible and remove snap ring.Pull rod assembly out of cylinder.Inspect components for excessive wearand damage. Tighten piston retainingnut to 100-115 ft.-lbs. Lubricate allseals and wipers prior to rod assemblyinstallation in cylinder.

ALL OTHER MODELS. Remove thesteering cylinder as outlined in para-graph 17 and proceed as follows:Remove fitting (8—Fig. 11 A) and pushthe rod guide (12) into cylinder tube farenough to remove snap ring (7). Usepiston and rod to bump guide (12) outof cylinder. Remove cap screw or nut(17) from end of rod and remove piston(13). Guide (12) can be withdrawn fromrod after piston is removed.

Carefully inspect all parts for scoringor excessive wear. Install piston rodscraper (4) with sharp edge of seal out.Install back-up ring (5) with rough sidetoward inside of cylinder. Install "0"ring (6) in same groove on inner side ofback-up ring. Install back-up ring (10)in outer groove of piston rod guide.Position "0" ring (11) in same groovebetween back-up ring and inner end ofrod guide. Install "0" ring (15) incenter groove of piston (13). Positionsealing ring (16) in center groove overthe "0" ring. On Model 200 install "0"ring (15) and back-up ring (16) side byside with "0" ring nearer piston nut.Install the two split wear rings (14) inthe two outer grooves in piston. Model200 has only one wear ring on piston.

Lubricate piston rod (3) and slide rodguide (with seals) over the rod. Installpiston (13) and tighten lock nut or capscrew (17). Lubricate the cylinder bore,piston and rod guide. Slide piston androd guide into cylinder and push rodguide into cylinder far enough to installsnap ring (7).

NOTE: Port in rod guide should be inline with hole in cylinder. Bump rodguide out against snap ring with pistonand install fitting (8).

internai (Duai) Cyiinders19. R&R AND OVERHAUL. The

front support casting on all tricyclemodels and some adjustable axle mod-els is used as the steering cylinder. Toremove front support, refer to para-graph 10. Remove adjustable axle, ortricycle pedestal from front support.Remove plug (11—Fig. 12), screw(lOA), washer (10) and shims (9).Steering shaft (1) can be removed fromthe bottom. Remove cylinder plugs (18)and withdraw pistons (16).

When reassembling, renew all seals.Install one back-up ring (14) and "0"ring (15) in cylinder, then insert piston(16) from opposite side of cylinder.Install a back-up ring (14) and "0" ring(15) on the other side of cylinder, thencenter the piston.

NOTE: Make certain that cut-away(tooth) portion of piston is not pushedthrough new seais (15) or leakage mayoccur.

Install other piston and seals andalign center tooth of both pistons (16)with centerline of hole (A). Installsteering spindle (1) with index mark onflange centered at the rear. Steeringshaft bearings (2 & 8) should be ad-

Fig. 12—Expioded view ofdual internal {Zipper) steer-ing front support. Frontsupport is used as steer-

ing cylinder.

1. Steering shaft2. Bearing cone3. Bearing cap4. Seal5. Front support6. Snap ring7. Bearing cup8. Bearing cone9. Shims (0.003 & 0.010)

10. WasherlOA. Cap screw11. Plug12. Filler cap13. Filler pipe14. Back up rings

(4 used)15. "0" rings (4 used)16. Pistons (2 used)17. "0" rings (4 used)18. End plugs (4 used)

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180-185-190-190XT-200-7000 Paragraphs 20-22

justed to a free rolling fit with no endplay by varying number and thicknessof shims (9). Cap screw (lOA) should betightened to 130-140 ft.-lbs. torque.Install "0" rings (17) on plugs (18).

Refer to paragraph 10 for installationprocedure, the same type of oil (AUis-Chalmers "Power Fluid") as used in thehydraulic system should be used infront support. Oil level should bemaintained at 2 inches from bottom asmeasured through breather tube (13).This oil is used to lubricate parts in thefront support. Fluid for power steeringis contained in Tower-Director" com-partment. Leakage past seals (15) willbe noticed by an excessive amount ofoil in front support housing.

ENGINE ANDCOMPONENTSR&R ENGINE ASSEMBLY

All Models20. To remove the engine, disconnect

all battery ground straps. If engine isto be disassembled, drain oil pan.Remove front support casting as out-lined in paragraph 9 or 10. Unbolt andremove both side rails.

NOTE: On models so equipped,detach hydraulic system fiiter fromengine left side raii.

Disconnect wires and cables fromengine electrical units. Disconnect hy-draulic tubes from the pump, removeclamps and reposition tubes away fromengine. Disconnect hourmeter cable,shut off fuel supply at tank and discon-nect fuel supply line from gasolinecarburetor, diesel injection pump orLP-Gas regulator. On diesel models,disconnect fuel return line, speed con-trol cable and pump shut-off cable. Onnon-diesel models, disconnect governorcontrol cable and choke cable.

NOTE: Depending on reason forengine removal, it may be easier toremove other components from engineat this time.

Attach hoist to lift hooks provided atfront and rear end of cylinder head,then unbolt and remove engine fromtorque housing.

Reinstall engine and clutch assemblyby reversing removal procedures. Bleedthe diesel fuel system as outlined inparagraph 60 and, if necessary, bleedthe power steering system as outlinedin paragraph 12.

CYLINDER HEAD

All Models21. REMOVE AND REINSTALL.

Drain the cooling system and remove

hood top panel and both hood rear sidepanels. On non-diesel models, shut offfuel at tank and remove inlet manifold,exhaust manifold and carburetor. Ondiesel models, remove the exhaustmanifold. Disconnect fuel lines frominjector nozzles and cap all openings aseach line is disconnected.

NOTE: Aithough not required forremovai of cylinder head, it Is re-commended that diesel fuei injectorassembiies be removed at this time.

The injector nozzle tips protrudethrough the flat bottom surface of cy-linder head and, if injectors are notremoved, extreme care must be takenwhen removing and handling the re-moved cylinder head.

On all models, disconnect upperradiator hose from thermostat housingand remove inlet tube from air cleaner.Disconnect by-pass tube from waterpump and thermostat housing, discon-nect wire from temperature gagesending unit and remove thermostathousing. Disconnect bypass tube fromwater pump and thermostat housing,disconnect wire from temperature gagesending unit and remove thermostathousing. Disconnect breather tube andremove the rocker arm cover. Removethe rocker arm assembly and pushrods. Remove cylinder head retainingcap screws and carefully pry cylinderhead up off dowel pins located at frontand rear of cylinder block. Lift cylinderhead from tractor.

When reinstalling cylinder head, besure that gasket surfaces of cylinderhead and block are clean and free ofburrs. Place new gasket with sidemarked *THIS SIDE DOWN" againstcylinder block and be sure gasket isproperly located on the two dowel pins.

NOTE: Do not appiy grease or gasicetseaier to gasicet surfaces, block orcylinder head; new gasket is treatedwith phenoiic sealer. Lubricate theretaining cap screws with motor oiibefore installing.

Install push rods and rocker arm as-sembly. Starting in center and workingtoward each end, tighten the cylinderhead retaining cap screws first to 63-73ft.-lbs. torque, then to final torque of150 ft.-lbs. The small rocker armbracket retaining cap screws on dieselmodels should be tightened to 28-33 ft.-lbs. torque. On non-diesel models, allrocker arm bracket retaining capscrews should be tightened to 18-20ft.-lbs. Adjust valve tappet gap cold asoutlined in paragraph 28.

When installing inlet and exhaustmanifolds, observe the following: Ondiesel models, tighten inlet manifoldretaining screws to 18-20 ft.-lbs. torque.

On late 190, late 190XT, 200, 7000 andall 180 and all 185 diesel models, theexhaust manifold retaining screws areself-locking type and should be tighten-ed to 30 ft.-lbs. torque. On early 190and 190XT diesel models, the retainingscrews are locked with tab washersand should be tightened to 44-49 ft.-lbs.torque. On all non-diesel models, thetwo cap screws attaching each end ofexhaust manifold should be tightenedto 30-33 ft.-lbs. and all other inlet andexhaust manifold attaching screwsshould be tightened to 44-49 ft.-lbs.

Start and run engine for approxi-mately 1 hour until it reaches normaloperating temperature (preferablyunder load); then, retorque cylinderhead, inlet manifold and exhaust mani-fold. Valve clearance should be ad-justed to recommended clearance hotas outlined in paragraph 28.

VALVES AND SEATS

Diesel22. Inlet valves have a face and seat

angle of 30 degrees. A one degreeinterference angle may be used bymachining the seat to 31 degrees. Seatwidth should be 3/32 inch and can benarrowed using 15 and 60 degreestones. Inlet valves seat directly oncylinder head of early models while arenewable valve seat insert is used onlater models. Standard and 0.005-inchoversize seat inserts are available forservice. When installing standard in-serts, machine 1.6035-1.6045 diametercounterbore to a depth of 0.3825-0.3835(measured from gasket surface ofcylinder head). Insert should have0.001-0.003 interference fit in counter-bore. If standard size insert is loose,install 0.005-inch oversize insert. Sur-face of inlet valve head must berecessed at least 0.0345 from cylinderhead surface to provide proper clear-ance between valve and piston. Inletvalve stem diameter is 0.3715-0.3720inch.

Exhaust valves have a face and seatangle of 45 degrees on all models ex-cept 200 and 7000 which have a 30degree seat. A one degree interferenceangle may be used by machining theseat to 46 degrees on all models except200 and 7000 which should be main-chined to 31 degrees. Seat width shouldbe 3/32 inch and can be narrowed using30 and 60 degree stones on all modelsexcept models 200 and 7000 which canbe narrowed using 15 and 60 degreestones. On early production 190 modelsand all 180 and 185 models, exhaustvalves seat directly in the cylinderhead. "One-Ninety** models after engineserial number (2D-03142) and all "XT**and all 200 and 7000 models are

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Paragraphs 23-27 ALLIS-CHALMERS

provided with renewable seat inserts.Counterbore for standard size seatinsert is 1.4805-1.4815 diameter anddepth is 0.4465-0.4485 (as measuredfrom gasket surface of cylinder head).Inserts should have 0.001-0.003 inter-ference fit. If new standard size insertis too loose, counterbore should bemachined for 0.005 oversize insert.Stake the cylinder head at three points120° apart near the exhaust seat insertafter seat is installed.

NOTE: Do not stake cylinder headnear the injector nozzle hole.

Surface of exhaust valve head shouldbe recessed at least 0.0485 fromcylinder head surface to provide properclearance between valve and piston.Exhaust valve stem diameter is 0.3705-0.3710.

Non-Diesel

23. Inlet valves have a face and seatangle of 30 degrees. Seat width shouldbe 3/32 inch and can be narrowed using15 and 60 degree stones. Inlet valvesseat directly on cylinder head, howeverseat inserts are available for service.When installing, service inserts on 180and 190 models with G2500 engine (3^4-inch bore), counterbore should be ma-chined 1.6085-1.6095 diameter and0.3345-0.3365 deep (as measured fromgasket surface of cylinder head). For190XT models with 3-7/8-inch cylinderbore, counterbore for inlet valve insertshould be 1.742-1.743 diameter and0.399-0.401 deep (as measured fromgasket surface of cylinder head). Theinsert should have 0.001-0.003 inter-ference fit in counterbore on all models.Surface of inlet valve head should berecessed 0.0345 from cylinder headsurface to provide proper clearancebetween valve and piston. Inlet valvestem diameter is 0.3715-0.3720.

Exhaust valves have a face and seatangle of 45 degrees. Seat width shouldbe 3/32 inch and can be narrowed using30 and 60 degree stones. Exhaustvalves seat on renewable type seatinserts. Counterbore for standard sizeseat inserts on 180 and 190 models with3%-inch cylinder bore should be 1.4805-1.4815 diameter and 0.3835-0.3855 deep(as measured from gasket surface ofcylinder head). For 190XT models with3-7/8-inch cylinder bore, counterborefor seat insert should be 1.614-1.615diameter and 0.4105-0.4125 deep (asmeasured from gasket surface of cy-linder head). Inserts for all modelsshould have 0.001-0.003 interference fit.If new standard size insert is too loose,counterbore should be machined for0.005 oversize insert. Cylinder headshould be punched at three equallyspaced locations to stake the valve seat

in position after installation. Surface ofexhaust valve head should be recessed0.0485 from cylinder head surface toprovide proper clearance betweenvalve and piston. Exhaust valve stemdiameter is 0.3705-0.3710.

VALVE GUIDES

All Models24. Inlet valve stem diameter is

0.3715-0.3720 and exhaust valve stemdiameter is 0.3705-0.3710. Desired stemto guide clearance if 0.001-0.0015 forinlet and 0.002-0.0025 for exhaust.Maximum allowable stem to guideclearance is 0.0035 for inlet valve and0.0055 for exhaust.

Inlet and exhaust valve guides areinterchangeable. When installing, pressguides into cylinder head from bottom,with the chamfered end up. Distancefrom valve spring counterbore in headto top of valve guide (Fig. 13) is asfollows:

Diesel-Inlet 21/32 inchExhaust 7/8 inch

Non-Diesel—Inlet 15/16 inchExhaust 31/32 inch

New guides should be reamed to0.373 diameter after installation to pro-vide correct stem to guide clearance.Valve guides in factory service replace-ment cylinder head are reamed tocorrect size at factory. Valves should bereseated after installing new guides.

VALVE SPRINGS

All Models25. The interchangeable intake and

exhaust valve springs should be re-

Fig. 1$—Vlew showing mathod of measuring¥ai¥e guide height abo¥e cyiinder headcounterbore when Installing new valve

guides. Refer to paragraph 24.

newed if rusted, distorted or if theyvary more than 5% from followingspecifications:

Model 7000Pounds pressure®

2.23 inches .51-63Pounds pressure®

1.78 inches 121-133Spring free length 2.86All Other ModelsPounds pressure @

2.223 inches 41-45Pounds pressure ©

1.836 inches 73-81Spring free length,

approx 2-31/32 inches

CAM FOLLOWERS

All Models26. The 0.748-0.7485 diameter mush-

room type cam followers (valve lifters)ride directly in unbushed cylinder blockbores and can be removed afterremoving the camshaft. Cam followersare available in standard size only andshould be renewed if either end ischipped or worn or if they are loosein cylinder block bores. Desired fol-lower to bore clearance is 0.001-0.0025.

ROCKER ARMS

All Models27. R&R AND OVERHAUL. Rocker

arms and shaft assembly can be re-moved after removing hood top andrear side panels, disconnecting breathertube and removing rocker arm coverand oiling tube. Loosen and remove allretaining cap screws equally, then liftrocker arms and shaft assembly fromthe cylinder head.

The hollow rocker arm shaft isdrilled for lubrication to each rockerarm. Lubricating oil to the rocker armoiling tube is supplied through a drilledpassage in cylinder head and engineblock.

Rocker arm shaft diameter is 0.999-1.000. Bore in rocker arm is 1.001-1.002providing a clearance of 0.001-0.003 be-tween shaft and rocker arms. Ifclearance is excessive, renew the shaftand/or rocker arms.

On non-diesel engines, rocker armsare offset toward shaft support bracket.On diesel engines, all rocker arms arealike.

Before reinstalling the rocker armassembly, loosen each tappet adjustingscrew about two turns to preventinterference between valve heads andpistons due to interchanged compo-nents. Tighten all of the rocker armsupport retaining cap screws on non-diesel models to 18-20 ft.-lbs. On dieselmodels, tighten long rocker arm sup-

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